Method and apparatus for inserting a spacer between annular reinforcement bands

ABSTRACT

A method is provided for making an annular reinforcement structure having inner and outer reinforcement bands maintained in concentric alignment by a resilient spacing element positioned between the bands. The method includes the steps of placing the spacing element against the inside face of the outer reinforcement band and compressing the spacing element with a jig, adjacent the top edge of the outer reinforcement band. The spacing element is sufficiently compressed to allow the inner reinforcement band to slide into concentric alignment with the outer reinforcement band, with a minimum of deflection and/or distortion of the inner reinforcement band.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and is a divisional of, U.S. patentapplication Ser. No. 13/561,272, entitled “Method and Apparatus ForInserting a Spacer Between Annular Reinforcement Bands” which was filedon Jul. 30, 2012, which claims priority to U.S. Provisional PatentApplication No. 61/536,695, entitled “Method and Apparatus For Insertinga Spacer Between Annular Reinforcement Bands” which was filed on Sep.20, 2011, both of which are entirely incorporated by reference herein.

JOINT RESEARCH AGREEMENT

The claimed invention was made under a joint research agreement betweenMilliken & Company and Michelin Americas Research Company, a division ofMichelin North America, Inc. The joint research agreement was in effectbefore the date the claimed invention was made, and the claimedinvention was made as a result of activities undertaken within the scopeof the joint research agreement.

FIELD OF THE INVENTION

This present invention relates to a method of inserting a resilientspacer between concentric annular reinforcement bands using a jig totemporarily compress the spacer.

BACKGROUND OF THE INVENTION

Various industrial products, such as belts for power transmission, hosesand tires, incorporate a reinforcement material in an elastomericmatrix, to achieve both strength and flexibility. For example, thereinforcing materials may be a textile fabric, a metal sheet, fibers orcords made up of organic polymers, inorganic polymers, metals andcombinations thereof. Manufacture of the composite product typicallyrequires that the spatial relationship of the reinforcement material andthe elastomeric matrix be consistent throughout.

In some circumstances, it may be advantageous to provide multiple layersof reinforcement material, wherein the layers are uniformly spacedapart, with the space between the reinforcement layers filled with asuitable matrix material, such as an elastomer. The present invention isdirected to a novel method of maintaining the spatial relationship ofmultiple reinforcement bands during the manufacturing process, inparticular, maintaining two annular bands in spaced-apart, concentricrelationship.

SUMMARY OF THE INVENTION

The spatial relationship of concentric, inner and outer reinforcementbands can be maintained by providing a resilient spacing element, in theannular space between the inner and outer bands. The spacing element maybe an annular band or a plurality of discrete shims, arranged in thespace between the inner and outer bands. Once the spacer is insertedbetween the inner and outer reinforcement bands, it can be held in placeby friction. In one embodiment of the invention, the thickness of thespacing element in the radial direction is greater than the spacebetween the inner and outer reinforcement bands, such that the spacingelement is compressed between the inner and outer reinforcement bands,thereby exerting force against the sides of the bands and increasingfrictional resistance to relative movement of the components.

The annular reinforcement structure of the present invention can beconstructed by the steps of placing a resilient spacing element againstthe inside face of the outer reinforcement band and compressing thespacing element against the inside face of the outer reinforcement bandwith a jig. The jig is proportioned to compress the spacing elementagainst the inside of the outer reinforcement band, adjacent the topedge of the reinforcement band, thereby creating sufficient space forthe inner reinforcement band to slide past the jig and the spacingelement.

The jig may be an annular band having a circumference that is less thanthe circumference of the outer reinforcement band and greater than acircumference of the inner reinforcement band, with the radial thicknessof the jig being less than the radial distance between the inner andouter reinforcement bands, when the reinforcement bands are concentric.Also within the scope of the invention is a jig having discrete clampsfor compressing a spacing element made up of a plurality of shims, whichare spaced around the circumference of the outer reinforcement band. Thestep of compressing the spacing element against the reinforcement bandmay be automated.

The present invention also includes a machine for compressing thespacing element, to facilitate placing the inner and outer reinforcementbands in concentric relationship. The machine has a plurality of plates,which are spaced around the inside circumference of the outerreinforcement bands. The plates each have a convex surface, whichengages and compresses the spacing element against the inside face ofthe outer reinforcement band, when the plates move from a retracted toan extended position. The plates move radially, in a track, relative tothe outer reinforcement band. The tracks are supported by a base. Themovement of the plates may be accomplished by providing the plates withpins, which engage one or more spiral grooves in an actuation plate,which rotates relative to the base. For example, as the actuation platerotates, the pin of each plate rides in the spiral groove to force theplate radially inward or outward in its track.

In the next step, the inner reinforcement band is slid in the axialdirection relative to the outer reinforcement band, from the top edge ofthe outer reinforcement band towards a bottom edge of the outerreinforcement band, while the spacing element is compressed by the jig.The inner reinforcement band is positioned inside the outerreinforcement band, with the inner and outer reinforcement bandsoriented concentrically. Once the inner reinforcement band slides pastthe jig, the jig can removed from between the inner reinforcement bandand the outer reinforcement band, and the spacing element is retained inplace between the inner reinforcement band and the outer reinforcementband.

In one embodiment of the invention, the jig compresses the spacingelement adjacent the top edge of the outer reinforcement band, but thejig does not extend downward, in the axial direction, as far as thebottom edge of the outer reinforcement band. Nevertheless, the spacingelement may extend in an axial direction from the top of the outerreinforcement band below the jig, and optionally, as far as the bottomedge of the outer reinforcement band. In other words, the spacingelement may be compressed by the jig adjacent the top edge of the outerreinforcement band only, with the portion of the spacing elementextending below the jig remaining in its uncompressed state. The innerreinforcement band is inserted into the structure, and the innerreinforcement band slides past the jig and slides against theuncompressed portion of the spacing element. Thus, the innerreinforcement band frictionally engages the spacing element, whichmaintains the spacing element in the desired orientation between theinner and outer reinforcement bands when the jig is removed.

The spacing element is a resilient material, that is, it can becompressed against the inside face of the outer reinforcement band bythe jig a sufficient distance to allow the inner reinforcement band toslide past, and the spacing element can expand once the jig is removed,to frictionally engage the inner reinforcement band. The spacing elementmay be a porous material, such as a polymer foam, in particular apolyurethane foam. By way of example, the spacing element may be anopen-cell polymer foam having a fraction of voids to net volume of 75%or greater. The polymer foam may be a reticulated foam having a fractionof voids to net volume of 90% or greater, such as a reticulatedpolyurethane foam.

The annular reinforcement structure may be incorporated into a matrixmaterial, such as an elastomer, and the relative spacing of the innerand outer reinforcement bands remains uniform during the manufacturingprocess. The annular reinforcement structure can be incorporated into amatrix material under conditions whereby the matrix material will flowinto the pores or voids in the spacing element, and is then cured.Additionally, the annular reinforcement structure may be embedded in thematrix material. In one embodiment of the invention, the spacing elementis a polyurethane foam and the matrix material is polyurethane polymerwhich fills the voids in the foam. The reinforcement bands may also beporous, and the matrix material may penetrate into the interstices inthe reinforcement bands, when the reinforcement structure is embedded ina matrix. Also within the scope of the invention is to permeate thespacing element with a first matrix material and embed the annularreinforcement structure in a second matrix material having a differentchemical composition that the matrix material introduced into thespacing element.

The invention has been described in terms of compressing the spacingelement against the inside face of the outer reinforcement band, tofacilitate insertion of the inner reinforcement band. Nevertheless, itcan be understood that the role of the inner and outer reinforcementbands may be reversed. In particular, the inner reinforcement band maybe supported from collapsing inward by a suitable form or die locatedinside the inner reinforcement band, and the spacing element iscompressed by a jig against the outside face of the inner reinforcementband. The outer reinforcement band can then be slid in an axialdirection to place the inner and outer reinforcement bands in concentricrelation, with the jig positioned between the spacing element and theouter reinforcement band.

The present invention includes a method of making an annularreinforcement structure, a method of making a reinforced matrixmaterial, as well an annular reinforcement structure and a reinforcedmatrix material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of the annular reinforcement structure.

FIG. 2 is a cut-away perspective view of the annular reinforcementstructure.

FIG. 3 is an exploded perspective view of the jig, spacing element andouter reinforcement band.

FIG. 4 is a top perspective view of the assembled jig, spacing elementand outer reinforcement band.

FIG. 5 is a top perspective view of an annular-shaped jig.

FIG. 6 is a top perspective view of the jig, spacing element and outerreinforcement band, wherein the spacing element is a plurality ofdiscrete shims.

FIG. 7 is an exploded view showing the inner reinforcement band beinginserted into the structure shown in FIG. 4.

FIG. 8 is a side cross-section view of the inner reinforcement bandbeing inserted into the structure shown in FIG. 4.

FIG. 9 is a top perspective view of a machine for assembling the annularreinforcement structure.

FIG. 10 is an exploded, bottom perspective view of the insertion machinefor assembling the annular reinforcement structure showing the mechanismfor retracting and extending the plates.

FIG. 11 is an exploded, top perspective view of the spacing element andouter reinforcement band being placed on the insertion machine.

FIG. 12 is a top perspective view of the spacing element and outerreinforcement band in place on the insertion machine.

FIG. 13 is an exploded, top perspective view of the plates extended tocompress the spacing element to allow insertion of the innerreinforcement band.

FIG. 14 is an exploded, top perspective view of the pin plates used todistribute force axially, when the annular reinforcement structure isremoved from the insertion machine.

FIG. 15 is a top perspective view showing the annular reinforcementstructure being removed from the insertion machine.

FIG. 16 is a top perspective view of the annular reinforcement structureembedded in a matrix material.

FIG. 17 is a side cross-section view of the annular reinforcementstructure embedded in a matrix material.

DETAILED DESCRIPTION OF THE INVENTION

Without limiting the scope of the invention, the preferred embodimentsand features are hereinafter set forth. All of the United Statespatents, published applications and unpublished pending applications,which are cited in the specification, are hereby incorporated byreference. Unless otherwise indicated, conditions are 25° C., 1atmosphere of pressure and 50% relative humidity, concentrations are byweight, and molecular weight is based on weight average molecularweight. The term “polymer” or “polymeric foam” as used in the presentapplication denotes a material having a weight average molecular weight(Mw) of at least 5,000. Such polymeric materials can be amorphous,crystalline, semi-crystalline or elastomeric polymeric materials.

Inner and Outer Reinforcement Bands

Referring to FIGS. 1 and 2, annular reinforcement structure 1 has innerreinforcement band 2, outer reinforcement band 3, and a spacing element4. The reinforcement structure may be made with a range of dimensions.By way of example, the width 5 of the annular reinforcement structure,also referred to herein as the width in the axial direction, may rangefrom 0.5 inches to 5.5 feet, and the outside diameter 6 may range from 3inches to 13 feet. By way of example, the distance between the innerreinforcement band 2 and the outer reinforcement band 3, when the bandsare concentric, shown as radial thickness 7, may range from 2 mm to 25mm.

In various embodiments of the invention it is desirable to allow forrelative movement of the inner and outer reinforcement bands withinannular reinforcement structure 1, such as may be caused by flexing orshear force. In such circumstances, the annular reinforcement band maybe provided with a minimum radial thickness 7 of 5 mm, between the innerand outer reinforcement bands. Applications for the annularreinforcement structure of the present invention, including suitablestructures, alignment and spacing of the reinforcement bands, may befound in U.S. Pat. No. 6,769,465 B2 and U.S. Pat. No. 7,650,919 B2.

Each of the reinforcement bands is a circular strip, characterized asbeing flexible in the radial direction and relatively inextensible incircumference. In one embodiment of the invention, the reinforcementbands are sufficiently flexible to be subjected to a bend radius that isone-tenth or less of the radius of the band when the band is oriented inthe shape of a circle, without experiencing a permanent set in the band.The inner and outer reinforcement bands may be the same or different,both in terms of materials of construction and design.

An advantage of the present invention is that it may be practicedwithout significant deflection or distortion of the reinforcement bands.Thus, while the reinforcement band may be flexible in a radialdirection, it is often desirable to avoid manufacturing steps that willrequire the reinforcement bands, especially the inner reinforcementband, to be crimped inward during assembly of the annular reinforcementstructure.

By way of example, the reinforcement band may be a woven or non-woventextile structure, arrangement of monofilament and/or multifilamentcords, bi-component yarns, spun yarns, braided cords, single ormultilayer sheets of polymers or metals, or a combination of theforegoing materials. By way of example, the reinforcement bands may beconstructed of fiberglass, rayon, nylon, aramid, polyester, carbon ormetal, such as steel. The materials may be treated to improveperformance, allow for easier manufacturing and/or improve bond strengthbetween materials. Examples include brass-plated steel, elastomer coatedcords and the use of adhesion promoters, such as resorcinol-formaldehydelatex. Further examples of suitable reinforcement bands may be found inbelts for power transmission, hoses, tires, rollers, strapping andgaskets.

By way of further example, materials having a Young's modulus (lb/in²),of 5,000,000 or greater, or even 10,000,000 or greater, are usefulherein. Alternatively, the stiffness of the reinforcement band and thematrix material filling the interstices in the polymer foam spacer maybe characterized by a relative Young's modulus of 1,000:1 or even10,000:1, respectively.

In one example, the reinforcement band may be a monofilament ormulti-filament cord wound into a helix and making at least threerevolutions. The multiple windings of the cord may be held together byrigid or flexible ribs arranged perpendicular to the cords, such as ayarn intertwined between adjacent cords, for example by weaving orknitting. The intertwined yarn may include fibers that can be melted tofuse the structure together, thereby providing stability to the band,especially in the axial direction. Examples of useful reinforcement bandstructures may be found in pending U.S. patent application Ser. No.12/661,196, filed Mar. 12, 2010, which is hereby incorporated byreference.

FIGS. 1 and 2 show inner reinforcement band 2 and outer reinforcementband 3 constructed of cord 8 and cord 9, respectively, wound intohelixes.

Also within the scope of the invention is the use of multi-plyreinforcement bands. For example, layers of reinforcement material mayoverlay one another, perhaps joined by a suitable binder, adhesive orstitch bond. The plies may be oriented parallel to each other or at anangle, for example, by winding one ply around the other in a spiral. Themulti-ply structures are considered as a single reinforcement bandherein.

Spacing Element

The spacing element may be a polymer foam structure, such as apolyurethane foam. In addition to polyurethane foam, which includespolyester-polyurethanes and polyether-polyurethanes, examples of polymerfoams include polystyrene, polyolefin, in particular polyethylene andpolypropylene, polyvinyl chloride, latex rubber, viscoelastic andmelamine resin foams. The cell structure of the foam can be controlledby suitable blowing agents, chemical and/or physical. Other additives,such as initiators, catalysts, cross-linking agents, and plasticizers,can be added to promote the reaction and modify the chemical andmechanical properties of the foam.

The foam may be an open-cell or closed-cell foam. Generally, open-cellfoam is believed to provide a greater range of applications,particularly when the annular reinforcement structure is embedded in amatrix material and the matrix material fills voids in the polymer foamspacer, as discussed in more detail herein. By way of example, thepolymer foams may have a fraction of voids to net volume of foam of 75%or greater, 85% or greater or even 95% or greater. The void fraction maybe increased by reticulating the polymer foam spacer, for example, bycombustion or chemical degradation. It may be advantageous to remove any“skin” formed on the outer surface of the polymer foam spacer, prior toreticulating the foam. Reticulated polyurethane foam having a fractionof voids to net volume of 90% or greater has been found to beparticularly useful.

Another material useful as the spacing element is a nonwoven textilematerial. By way of example, nonwoven textile materials with thickfilaments that are crimped or textured, such as a two or threedimensional corrugated configuration, are believed to be useful in thepresent invention. Nonwovens with thickness oriented fibers (“z”oriented fibers) can provide resilient properties to the nonwoven.

Yet another material useful as a spacing element is a woven or knittedtextile fabric. By way of example, the spacing element may be a fabricthat has two face layers separated by fibers or yarns extending betweenthe two layers. The fibers between the two layers provide a spring-likeforce that opposes the compression of the fabric. The fabric can bedesigned to meet design parameters, such as openness, pore shape, poresize, stiffness, direction of the separating fiber or yarn, affinity ofthe fabric to the matrix material, and the like.

Spacing elements having a wide range of physical properties, such asresilience, cell structure and porosity can be employed, depending uponthe intended application of the annular reinforcement structure. Formost applications, it is desirable that the spacing element hassufficient resilience to be handled without damage, yet be capable ofmaintaining the relative spacing and alignment of the inner and outerreinforcement bands during subsequent manufacturing steps. In oneembodiment of the invention, the polymer foam spacer is elastomeric,that is, the spacer can elastically recover from 30% compression orgreater. Polymer foam spacers that can elastically recover from 50%compression, or even from 80% compression or greater, may beadvantageous in certain applications.

The spacing element is preferably thicker in the radial direction thanthe radial distance between the inner and outer reinforcement bands,when the bands are positioned concentrically. Accordingly, when theannular reinforcement structure is assembled, the spacing element willfrictionally engage the outside face of the inner reinforcementstructure and the inside face of the outer reinforcement structure, tomaintain the relative position of the components. By way of example, theradial thickness of the spacing element may be 5% or greater, or even10% or greater, than the radial distance between the inner and outerreinforcement bands, when the bands are positioned concentrically.Providing a spacing element with substantially uniform thickness in theradial direction promotes even pressure against the inner and outerreinforcement bands, around the circumference of the annularreinforcement structure.

The shape of the spacing element may be an annular band, which includesa strip of material formed into a continuous ring, or a strip ofmaterial formed into a ring, with the loose ends loose abutting eachother or in close proximity. The annular band is preferably flexible,such that the spacing element can be deformed to facilitate insertingthe spacing element against the inner face of the outer reinforcementband, during assembly of the annular reinforcement structure, withoutcausing permanent deformation. By way of example, the spacing elementcan be subjected to a bend radius that is one-tenth or less of itsnormal (unflexed) inside diameter, without experiencing a permanent setto the material.

Alternatively, the spacing element may be a plurality of discrete shims,spaced around the circumference of the annular reinforcement structure,as shown in FIG. 6, whereby the number and size of the shims issufficient to maintain the relative alignment of the inner and outerreinforcement bands during handling and subsequent manufacturing steps.By way of example, an annular reinforcement structure having an outercircumference of 30 inches, may be supported by from 2 to 15 shimsevenly distributed around the circumference. The discrete spacingelements may be a polymer foam or textile material, as previouslydescribed.

The spacing element is preferably porous, to receive a matrix material,that is, the matrix material permeates interstices or voids in thespacing element, when the annular reinforcement material is embedded ina matrix material.

Also within the scope of the invention is to employ a spacing elementthat is removable from between the inner and outer reinforcement bands,after the spacing element has achieved its function of maintaining therelative alignment of the reinforcement bands. The removable spacingelement may be non-porous.

Jig and Method of Compressing the Spacing Element During Assembly

The annular reinforcement band of the present invention is assembled bycompressing the spacing element against a first reinforcement band,thereby allowing the second reinforcement band to be slid in an axialdirection past the spacing element and, placing the two reinforcementbands in a concentric relationship. The spacing element is compressedusing a jig, which is dimensioned to maintain compression, withoutcausing interference when the second reinforcement band is slid intoplace.

The method of assembling the annular reinforcement structure of thepresent invention is primarily described using the example of thespacing element first compressed against the inside face of the outerreinforcement band. It can be understood, however, that the firstreinforcement band may be the outer reinforcement band or the innerreinforcement band. If necessary to maintain the shape of thereinforcement band during the assembly steps, a suitable form or die maybe employed inside the inner reinforcement band or outside the outerreinforcement band.

Another advantage of the present invention is that it allows the spacingelement to be compressed radially without significant distortion orstretching of the spacing element in a circumferential dimension, whichmay cause thin and thick regions around the circumference.

The jig compresses the resilient spacing element against the inside faceof the outer reinforcement band, adjacent the top edge of thereinforcement band, thereby creating sufficient space for the innerreinforcement band to slide past the jig and the spacing element. Thus,the inner reinforcement band may be inserted into the annularreinforcement structure, with little or no inward deflection of theinner reinforcement band. The invention is particularly useful inconjunction with an inner reinforcement band constructed from a cordthat has been wound into a helix, such as a monofilament ormultifilament steel cord.

The jig may be an annular band having a circumference that is less thanthe circumference of the outer reinforcement band and greater than acircumference of the inner reinforcement band. When the spacing elementis compressed by the jig against the inside face of the outerreinforcement band, the inside face of the jig has a greatercircumference than the inner reinforcement band, thereby allowing theinside reinforcement band to slide by the jig, unobstructed. In otherwords, the combined radial thickness of jig and the compressed spacingelement is less than the radial distance between the inner and outerreinforcement bands, when the reinforcement bands are concentric.

Referring to FIGS. 3-4, jig 10 may be constructed from a cord 11 thathas been wound into a helix, such as a monofilament or multifilamentsteel cord, which may be brass-plated. Ribs 12 are spaced around thecircumference of jig 10 and arranged perpendicular to cords 11. The ribsengage and maintain the orientation of the cords in the annular band.The jig is sufficiently flexible to bend inward, thereby facilitatinginsertion inside the circumference of the outer reinforcement band, yetbe sufficiently spring-like to exert compressive force against thespacing element, to create an opening to slide the inner reinforcementband into the structure. The jig may be produced on a coil-windingmachine.

FIG. 3 shows an exploded view of jig 10, spacing element 4 and outerreinforcement band 3. The outer reinforcement band 3 has inside face 13and ribs 14. The assembled jig 10, spacing element 4 and outerreinforcement band 3 is shown in FIG. 4.

Referring to FIG. 5, jig 16 may be a strip of material formed into aring, with the loose ends 17 and 18 abutting each other or in closeproximity, which allows the circumference of jig 16 to be easilydecreased and expanded, for insertion and compression of the spacingelement, respectively. Jig 16 is believed to be useful for massproduction of the annular reinforcement structure. The design andimplementation of automated machinery for inserting the jig, compressingthe spacing element, and removing the jig after the inner reinforcementband is inserted into the structure is known to those skilled in the artof robotics. The machinery design should accommodate clearance for theinsertion of the inner reinforcement band.

Referring to FIG. 6, a jig is provided having discrete clamps 19 forcompressing a spacing element made up of a plurality of shims 20, whichare spaced around the circumference of the outer reinforcement band. Thejig may be constructed of plate 21 and backing 22, joined together bybracket 23, set at the desired distance to compress the spacing elementand create the clearance for inserting the inner reinforcement band.Clamps 19 may be arcuate shaped, to conform to the curve of the outerreinforcement band. The function of the clamps can be automated for massproduction of the annular reinforcement structure, for example withrobotic machinery, without interfering with or requiring deflection ofthe inner reinforcement band, when the inner reinforcement band isinserted.

In one embodiment of the invention, the jig compresses the spacingelement adjacent the top edge of the outer reinforcement band, but thejig does not extend downward, in the axial direction, as far as thebottom edge of the outer reinforcement band. Nevertheless, the spacingelement may extend in an axial direction from the top of the outerreinforcement band below the jig, and optionally, as far as the bottomedge of the outer reinforcement band. In other words, the spacingelement may be compressed by the jig adjacent the top edge of the outerreinforcement band only, with the portion of the spacing elementextending below the jig remaining in its uncompressed state. Referringto FIGS. 4 and 7, the axial width of jig 10 is less than the axialwidths of spacing element 4 and outer reinforcement band 3, and spacingelement 4 extends as far as the bottom edge 24 of the outerreinforcement band 3. Additionally, it can be seen from FIG. 8, that theradial thickness 25 of spacing element 4 is slightly greater than theradial distance between the inner and outer reinforcement bands. FIG. 6shows an example where the relative widths of clamps 19 is less than thewidths of spacing elements 20 and outer reinforcement band 3.

Referring to FIGS. 7 and 8, inner reinforcement band 2 is inserted intothe assembly of jig 10, spacing element 4 and outer reinforcement band 3shown in FIG. 4. The inner reinforcement band 2 slides past jig 10 andslides against the uncompressed portion of spacing element 4. Thus, theinner reinforcement band frictionally engages the spacing element, whichmaintains the spacing element in the desired orientation between theinner and outer reinforcement bands when the jig is removed.

Referring to FIG. 8, a side cross section view of the assembly of FIG. 4shows how jig 10 compresses spacing element 4 against the inside face 13of outer reinforcement band 3. The compression of spacing element 4occurs adjacent the top 15 of outer reinforcement band 3, therebyallowing inner reinforcement band 2 to be inserted into the assembly,without bending or distortion. While annular jig 10 is shown incombination with an annular spacing element, it can be understood thatan annular-shaped jig can also be used to compress a spacing elementcomprising a plurality of discrete shims.

Referring to FIGS. 9-15, a spacing element insertion machine and itsoperation is illustrated. Insertion machine 30 has base 31, whichsupports plates 32, spaced around the circumference of base 31. Plates32 have an arcuate shape, whereby convex side 33 is designed to engageand uniformly compress the spacing element against the inside face ofthe outer reinforcement band. The radii of the arcuate plates 32 may beselected so that plates 32 represent the arcs of a circle, when theplates are extended to compress the spacing element, prior to insertionof the inner reinforcement band.

FIG. 9 shows removable frame 34, which is temporarily supported by base31, but can be lifted upward relative to base 31 and plates 32, bypulling handle 35. Frame 34 has hub 36 and spokes 37, which extendbetween gaps in plates 32. Rim 38 connects spokes 37. Holes are providedin hub 36, allowing frame 34 to slide along guides 39, for example, whenthe assembled annular reinforcement structure is lifted off of insertionmachine 30, as shown in FIG. 15.

Referring to FIG. 10, the mechanism for retracting and extending plates32 in a radial direction is shown. Plates 32 slides radially incorresponding tracks 40, which are supported by base 31. Tracks 40 maybe integrally formed in base 31 as shown in FIG. 10, for example bycutting slots in base 31, or may be affixed to the surface of base 31,or may be some combination thereof. Tracks 40 are configured to allowradial movement of plates 32 outward from the center of base 31, whilemaintaining plates 32 in alignment relative to the outer reinforcementband, so that uniform pressure is applied to the spacing element duringthe compression step. In one example, each of the lower portion ofplates 32 and tracks 40 may be provided with corresponding tongue andgroove features, which prevent plates 32 from tilting during operation.

The bottom portions of each of plates 32 have pins 41 extendingdownward, past the underside of base 31. Pins 41 engage one of spiralgrooves 42 in actuation disk 43, which can be rotated on spindle 44,affixed to base 31. Actuation disk 43 can be rotated by turning arms 45,as shown, or the movement can be automated by any of a variety ofmechanisms, such as by an axle affixed to the actuation disk 43 or acombination of teeth on the outer circumference of actuation disk 43 andgears engaging the teeth.

In one embodiment of the invention, spiral grooves 42 are not cutcompletely through actuation disk 43, and the lower tips of pins 41 areeach provided with a small ball bearing, which rides in spiral grooves42.

Referring to FIGS. 11 and 12, outer reinforcement band 46 and spacingelement 47 are placed around plates 32, while plates 32 are in theirretracted position, that is, drawn inward to the center of base 31. Inone embodiment of the invention, spacing element 47 is placed againstthe inside face 48 of reinforcement band 46, before the outerreinforcement band and the spacing element are positioned on insertionmachine 30. As shown in FIG. 12, outer reinforcement band 46 and spacingelement 47 are placed on frame 34, which is supported on base 31.

Next, plates 32 are extended radially outward by rotating actuation disk43 to compress spacing element 47 against the inside face 48 of outerreinforcement band 46, prior to insertion of inner reinforcement band49, as shown in FIG. 13. Thus, it is possible to assemble the annularreinforcement structure 50, shown in FIG. 15, without kinking orotherwise causing the circumference of inner reinforcement band 49 to betemporarily reduced to fit within the spacing element.

Referring to FIGS. 14 and 15, the process of separating annularreinforcement structure 50 from insertion machine 30 may be facilitatedby employing pin plates 51, each having an array of pins 52 distributedalong their length. Pins 52 penetrate outer reinforcement band 46,spacing element 47 and inner reinforcement band 49, and may extendthrough inner reinforcement band 49. The bottom of pin plates 51 rest onspokes 37 of frame 34. Thus, pins 52 are spaced both axially andcircumferentially around annular reinforcement structure 50.

Annular reinforcement structure 50 is separated from insertion machine30 by lifting on handle 35 to raise frame 34, with spacing element 47retained between the outer reinforcement band 46 and the innerreinforcement band 49. Force is distributed to annular reinforcementstructure 50 by frame 34, pin plates 51 and pins 52. Accordingly, whenannular reinforcement structure 50 and insertion machine 30 areseparated, the force is distributed evenly, rather than acting only onthe bottom edge of annular reinforcement structure 50.

Prior to lifting frame 34, plates 32 may be partially retracted, therebydecreasing the frictional resistance between the convex side 33 ofplates 32 and spacing element 47. Plates 32 may be provided with acoating, such as polytetrafluoroethylene, to reduce friction.

In the method of placing a resilient spacing element against the insideface of the outer reinforcement band and compressing the spacing elementwith a jig, no particular order of assembly is required. For example,the spacing element may be inserted against the inside face of the outerreinforcement band first, and the jig inserted against the spacingelement second. Alternatively, the jig may be inserted within the outerreinforcement band first, and the spacing element inserted between thejig and the inside face of the reinforcement band second, such as bydeflecting the jig radially inward to accommodate the spacing element.

The method of making the annular reinforcement structure disclosedherein for two reinforcement bands and a spacing element could berepeated with a third reinforcement band and second spacing element, toproduce an annular reinforcement structure having three reinforcementbands, with each band separated by a spacing element. For example,employing the methods and apparatus disclosed herein, it is possible tofirst assemble an outer reinforcement band and an intermediatereinforcement band with a spacing element interposed between, followedby assembly of the inner reinforcement band with a second spacingelement between the inner reinforcement band and the intermediatereinforcement band.

Reinforced Matrix Material

The annular reinforcement structure of the present invention may be usedto reinforce a matrix material. The annular reinforcement structure maybe covered with the matrix material, that is, the matrix material coversat least one surface of the structure, for example, the outside face ofthe outer reinforcement band. The annular reinforcement structure may beembedded in the matrix material. It is also within the scope of theinvention for spacing element to be porous and the matrix material topermeate the pores, followed by curing the matrix material. In stillanother embodiment of the invention, a first matrix material may beintroduced into the space between the inner and outer reinforcementbands, and a second matrix material may be used to cover the surface ofor embed the annular reinforcement structure.

Referring to FIGS. 16 and 17, the annular reinforcement structure 1 isshown embedded in a matrix material 26, to create reinforced ring 27.Depending on the selection of the matrix material, whether the spacingelement is porous, such as an open-cell polymer foam, and the processingconditions, the matrix material may or may not permeate the spacingelement. In the embodiment of the invention shown in FIG. 16, the matrixmaterial has permeated the open-cell spacing element 4 and the voids inthe polymer foam are filled with matrix material 26.

The matrix material may be selected from a wide range of organic andinorganic materials, especially those that may be cast with the annularreinforcement structure embedded therein. By way of example, the matrixmaterial may be a natural or synthetic polymer, including thermoplasticand thermosetting materials. Of particular interest are elastomericmatrix materials, such as natural or synthetic rubber, polyurethane,segmented copolyester, polyamide co-polymer and thermoplasticelastomers. In one embodiment of the invention, spacing element 4 is areticulated, polyurethane foam and the matrix material 26 is apolyurethane polymer formed without a blowing agent, that is,substantially without voids, which permeates the voids in thepolyurethane foam. In another example, the matrix material is a ceramic,concrete or organometalic compound.

Also within the scope of the present invention are processes in whichthe spacing element is a polymer foam, and the polymer is a relativelylow melting temperature thermoplastic and is partially or completelymelted during the process of embedding the annular reinforcementstructure in a matrix material. For example, a thermoplastic polymerfoam spacer could be melted by the introduction of a matrix material,either because the matrix material is heated or involves an exothermicreaction. Alternatively, the polymer foam spacer could be melted ordissolved, prior to introduction of the matrix material, after thespacer has served its function of maintaining the relative orientationof the inner and outer reinforcement bands.

The invention may be further understood by reference to the followingclaims.

What we claim is:
 1. A method of making an annular reinforcementstructure having a first reinforcement band and a second reinforcementband, and a resilient spacing element positioned between the first andsecond reinforcement bands, maintaining the first and secondreinforcement bands in a spaced apart, concentric relationship,comprising the steps of: (a) placing the resilient spacing elementagainst a face of the first reinforcement band; (b) compressing theresilient spacing element against the face of the first reinforcementband, adjacent a top edge of the first reinforcement band, with a jig;(c) sliding the second reinforcement band in an axial direction relativeto the first reinforcement band, from the top edge of the firstreinforcement band towards a bottom edge of the first reinforcementband, while the resilient spacing element is compressed by the jig,whereby the first and second reinforcement bands are concentric, and thejig is positioned between the resilient spacing element and the secondreinforcement band; and (d) removing the jig from between the firstreinforcement band and the second reinforcement band, whereby theresilient spacing element is retained in place between the first andsecond reinforcement bands; and wherein the first and secondreinforcement bands are each comprised of a cord selected from the groupconsisting of monofilament or multi-filament yarns, and the cord iswound into a helix making at least three revolutions.
 2. The method ofclaim 1, wherein the resilient spacing element has a thickness in theradial direction that is greater than the radial distance between thefirst and second reinforcement bands, when the bands are in a concentricrelationship.
 3. The method of claim 2, wherein the resilient spacingelement is an open-cell, polymer foam having a fraction of voids to netvolume of 75% or greater.
 4. The method of claim 2, wherein theresilient spacing element is a reticulated, polyurethane foam having afraction of voids to net volume of 90% or greater.
 5. The method ofclaim 1, wherein the jig is an annular band having a circumference thatis intermediate in value relative to a circumference of the firstreinforcement band and a circumference of the second reinforcement band.6. The method of claim 1, wherein the jig has a width in the axialdirection that is less than a width of the first reinforcement band inthe axial direction and less than a width of the spacing element in theaxial direction.
 7. The method of claim 6, wherein the resilient spacingelement extends in the axial direction from the top of the firstreinforcement band to a distance below the jig, when the resilientspacing element is compressed against the face of the firstreinforcement band, and the second reinforcement band frictionallyengages the resilient spacing element below the jig, prior to removal ofthe jig from between the second reinforcement band and the resilientspacing element.
 8. The method of claim 1, wherein the resilient spacingelement is an annular band comprising an open-cell, polymer foam.
 9. Themethod of claim 1, wherein the resilient spacing element is comprised ofa plurality of discrete shims comprising an open-cell, polymer foam. 10.The method of claim 1, wherein the jig is comprised of a plurality ofplates, which are spaced around a circumference of the firstreinforcement band, each of the plates has a curved surfacecorresponding to a curvature of the first reinforcement band, and thecurved surfaces engage the spacing element when the plates are movedfrom a retracted position to an extended position.
 11. The method ofclaim 1, wherein the jig is an annular band.
 12. A method of making anannular reinforcement structure, comprising the steps of: (a) placing aresilient spacing element against an inside face of an outerreinforcement band, wherein the resilient spacing element is selectedfrom the group consisting of (i) an annular band, and (ii) a pluralityof discrete shims, arranged around a circumference of the outerreinforcement band; (b) compressing the resilient spacing elementagainst the inside face of the outer reinforcement band, with a jig; (c)sliding an inner reinforcement band in an axial direction relative tothe outer reinforcement band, from a top edge of the outer reinforcementband towards a bottom edge of the outer reinforcement band, while theresilient spacing element is compressed by the jig, whereby the innerreinforcement band is positioned inside the outer reinforcement band andthe resilient spacing element, and the inner and outer reinforcementbands are concentric; (d) removing the jig from between the innerreinforcement band and the spacing element, whereby the resilientspacing element is retained in place between the inner reinforcementband and the outer reinforcement band; and wherein the jig is comprisedof a plurality of plates, which are spaced inside a circumference of theouter reinforcement band, each of the plates has a convex surface, whichcompresses the spacing element against the inside face of the outerreinforcement band, when the plate is moved from a retracted position toan extended position.
 13. The method of claim 12, wherein the resilientspacing element has a thickness in the radial direction that is greaterthan the radial distance between the inner and outer reinforcementbands, when the bands are concentric.
 14. The method of claim 12,wherein the resilient spacing element is an open-cell, polymer foamhaving a fraction of voids to net volume of 75% or greater.
 15. Themethod of claim 12, wherein the resilient spacing element is areticulated, polyurethane foam having a fraction of voids to net volumeof 90% or greater.
 16. The method of claim 12, further including thestep of retracting the plates, to allow the resilient spacing element toexpand inward toward the inner reinforcement band and decrease thefriction between the plates and the resilient spacing element, after theinner reinforcement band is positioned inside the outer reinforcementband and the resilient spacing element, and before removing the jig frombetween the inner reinforcement band and the resilient spacing element.17. The method of claim 12, wherein each of the plurality of platesmoves from a retracted to an extended position by sliding in a track,wherein the tracks are aligned in a radial direction relative to theouter reinforcement band, and the tracks are supported by a base. 18.The method of claim 17, wherein each of the plates has a pin thatengages a spiral groove in an actuation disk, the disk is alignedparallel to the tracks and rotatable relative to the base, wherebyrotating the disk in one direction relative to the base radially extendsthe plates and rotating the disk in an opposite direction relative tothe base radially retracts the plates.
 19. The method of claim 12,wherein the jig is removed from between the inner reinforcement band andthe resilient spacing element by the relative movement between the jigand the annular reinforcement structure in the axial direction, andwherein the annular reinforcement structure is engaged by a plurality ofpins spaced axially and circumferentially around the annularreinforcement structure, which transfer force to the annularreinforcement structure in the axial direction.
 20. The method of claim12, wherein the jig is an annular band, and the jig has a width in theaxial direction that is less than a width of the outer reinforcementband in the axial direction and less than a width of the resilientspacing element in the axial direction.
 21. The method of claim 20,wherein the resilient spacing element extends in the axial directionfrom a top of the outer reinforcement band to a distance below the jig,when the resilient spacing element is compressed against the face of theouter reinforcement band, and the inner reinforcement band frictionallyengages the resilient spacing element below the jig, prior to removal ofthe jig from between the inner reinforcement band and the resilientspacing element.
 22. The method of claim 12, wherein the resilientspacing element is an annular band comprising an open-cell, polymerfoam.
 23. The method of claim 12, wherein the resilient spacing elementis comprised of a plurality of discrete shims comprising an open-cell,polymer foam.
 24. The method of claim 12, wherein the inner and outerreinforcement bands are each comprised of a cord selected from the groupconsisting of monofilament or multi-filament yarns, and the cord iswound into a helix making at least three revolutions.
 25. A method ofmaking a reinforced matrix material, comprising the steps of: (a)placing a resilient, porous spacing element against a face of a firstreinforcement band; (b) compressing the resilient, porous spacingelement against the face of the first reinforcement band, adjacent a topedge of the first reinforcement band, with a jig; (c) sliding a secondreinforcement band in an axial direction relative to the firstreinforcement band, from the top edge of the first reinforcement bandtowards a bottom edge of the first reinforcement band, while theresilient, porous spacing element is compressed by the jig, whereby thefirst and second reinforcement bands are in a concentric relationship,and the jig is positioned between the resilient, porous spacing elementand the second reinforcement band; and (d) removing the jig from betweenthe first reinforcement band and the second reinforcement band, wherebythe resilient, porous spacing element is retained in place between thefirst and second reinforcement bands; (e) introducing a liquid matrixmaterial in the space between the first reinforcement band and secondreinforcement band and curing the liquid matrix material; and whereinthe first reinforcement band is positioned around the secondreinforcement band, when the first and second reinforcement bands areconcentric.
 26. The method of claim 25, wherein the resilient, porousspacing element has a thickness in the radial direction that is greaterthan the radial distance between the first and second reinforcementbands, when the bands are concentric.
 27. The method of claim 26,wherein the resilient, porous spacing element is an open-cell, polymerfoam having a fraction of voids to net volume of 75% or greater.
 28. Themethod of claim 26, wherein the resilient, porous spacing element is areticulated, polyurethane foam having a fraction of voids to net volumeof 90% or greater.
 29. The method of claim 26, wherein the resilient,porous spacing element is a polyurethane foam, and the matrix materialis a polyurethane polymer, and the matrix material fills the voids inthe resilient, porous spacing element.
 30. The method of claim 25,wherein the first and second reinforcement bands are each comprised of acord selected from the group consisting of monofilament ormulti-filament yarns, and the cord is wound into a helix making at leastthree revolutions.
 31. The method of claim 30, wherein the cords arebrass-plated steel, the resilient, porous spacing element is apolyurethane foam, and the matrix material is a natural or syntheticelastomeric polymer.
 32. The method of claim 25, wherein the jig iscomprised of a plurality of plates, which are spaced around acircumference of the first reinforcement band, each of the plates has acurved surface corresponding to a curvature of the first reinforcementband, and the curved surfaces engage the resilient, porous spacingelement when the plates are moved from a retracted position to anextended position.
 33. The method of claim 25, wherein the jig is anannular band.
 34. The method of claim 25, wherein the first and secondreinforcement bands and resilient, porous spacing element are embeddedin the matrix material.
 35. The method of claim 25, further comprisingthe step of embedding the first and second reinforcement bands andresilient, porous spacing element in a secondary matrix material,wherein the matrix material and the secondary matrix material havedifferent chemical compositions.
 36. The method of claim 25, wherein theresilient, porous spacing element is an open-cell, polymer foam, and thematrix material permeates pores in the foam and is cured.
 37. The methodof claim 36, further comprising the step of embedding the first andsecond reinforcement bands in a secondary matrix material, wherein thematrix material and the secondary matrix material have differentchemical compositions.